1981 430XC kick start, idler and clutch question

[tcob]

I just had my clutch cover welded today due to a crack and will be in the process of re-installing it as soon as the gasket gets here. But some new questions have come up.
First question is, with the clutch cover off, even though I hold the short shaft of the kick start gear solid, I can still wiggle (rock) the gear back and forth. I can do the same with the idler gear, the one that sits partially behind the clutch basket. Is this normal? I plan on replacing the needle bearings for peace of mind.
Second question is how can I tell if I have the 1983 upgraded cases that were mentioned in another thread? The reason I ask is because this motor seems to be a mix of parts. Bike is titled as an 1981. It has a 1982 head and cylinder. Motor appears to have been stroked with a now welded crank. The shifter shaft has the later style (1983) two o-rings instead of one. Numbers on the motor are 2087 1545. I've included a picture of the shaft/bearing behind the clutch.
Third question. Does anyone know the actual size of the o-rings for the shift shaft and kick starter? The size is not listed in the parts manual.

Thank you for any advice.

 

[fran...k.]

The earlier case half does not have tapped holes that help mount the intermediate shaft.

 

[silverstreakNZ]

The little gear on the back of the clutch has next to no teeth on it ? Well it looks that way to me . Looks like it's gone past the rooted stage where the teeth look pointed to the stage where all the pointed bits have broken off and it's just nubby .
It's the 886 gear . Common problem .
One theory is the long plastic needle bearing inside the clutch lets it wobble too much and to replace it with two shorter needle bearings

 

[Joe Chod]

gear on back of basket goes because Husky never heat treated them well///thats the bottom line

 

[Bigbill]

I've seen this wear on the gear on the rear of the clutch basket before. Finding a good clutch basket with little wear is rare. Doing the heat treating is a double edge sword too little it wears too much it's more brittle. It's a fine line to get it right. I wonder if using a light weight oil makes it wear more. A thicker weight oil has more cushion. The loose bearing fit can add to the problem. I wish I was working now to do a Rockwell test on the hardness.

Everytime I see a case opened up I get impressed on how much engineering goes into these engines and transmissions. All the manufacturing to make it too.

 

[tcob]

I went ahead and ordered both needle bearings and new o-rings for both the shift shaft and kick start shaft from husqvarna-parts. I also ordered a new bearing for the clutch because it was the plastic cage type. Hopefully the new bearings will "stiffen" the assembly up. I also ordered the replacement aluminum clutch cover from hva-factory as well. The teeth on the clutch basket appear ok to me and it is the 886 gear. I included a better picture now that I have things apart.

 

[silverstreakNZ]

Oh yea they are fine . Now I see it . The first picture they looked rounded right off . But yea you're on the right track to doing everything to look after that gear

 

[2premo]

the one thing that gets overlooked is the level
if not full the bearings run dry and do a bunch of damage
it is to the bottom of the fill hole angle where it meets the flat surface of the cover
1 quart is not enough by the way

 

[Picklito]

Right. It's close to 1500cc. A good feature of this engine.

Are you guys using the steel cage clutch bearing from Suzuki?

 

[justintendo]

i have some husky steel one piece bearings..i got one from husqvarnaparts but i guess the supply is getting pretty dry on those..

 

[86 400 XC]

i have some husky steel one piece bearings..i got one from husqvarnaparts but i guess the supply is getting pretty dry on those..

I bought 5 last month